PRESENTATION

WORKSHOP TECHNOLOGY 2
JJ204
GROUP MEMBERS
KATHIRAVAN S/O PARAMASIWAN
NAAVINDRA PRASAD S/O GANESAN
SIM KAH TIANG

INTRODUCTION
GAS SHIELDED ARC WELDING
The primary goal of any welding operation is to make a weld that
has the same properties as the base metal.
The only way to produce such-a weld is to protect the molten puddle
from the atmosphere
The two general types of gas shielded-arc welding processes are
gas tungsten-arc welding (GTA) and gas metal-arc welding (GMA).
GTA is often tilled TIG (tungsten inert gas) and GMA is referred to as
MIG(metal inert gas).
The term inert refers to a gas that will not combine chemically with
other elements

GAS SHIELDED ARC WELDING

PRINCIPLE

TUNGSTEN INERT GAS

Gas tungsten arc welding (GTAW), also known as tungsten inert gas
(TIG) welding
Is an arc welding process that uses a non-consumable tungsten
electrode to produce the weld
Enables the metals and wide range of ferrous alloys to be welded
without the use of flux
The weld area is protected from atmospheric contamination by an
inert shielding gas (argon or helium)

GTAW is most commonly used to weld thin sections of stainless

steel and non-ferrous metals such as aluminum, magnesium, and
copper alloys

METAL INERT GAS

Gas metal arc welding (GMAW), sometimes referred to by its

subtypes metal inert gas (MIG) welding or metal active gas (MAG)
welding

Is a welding process in which an electric arc forms between a

consumable wire electrode and the workpiece metal(s), which heats
the workpiece metal(s), causing them to melt, and join

Is a process which suitable for welding aluminium,magnesium

alloys,plain and low alloy steels,stainless and heat-resistant
steel,copper and bronze

The process can be semi-automatic or automatic

DIFFERENCE BETWEEN
GAS SHIELDED ARC WELDING
AND
NORMAL ARC WELDING

ARC WELDING
Arc welding is a type of welding that uses
a welding power supply to create an
electric arc between an electrode and the
base material to melt the metals at the
welding point
They can use either direct (DC) or
alternating (AC) current,

GAS SHIELDED ARC WELDING

Shielding gases are inert or semi-inert gases that are commonly

used in several welding processes

Inert gases:helium,argon
Semi-inert:oxygen,carbon dioxide,hydrogen,nitrogen

Their purpose is to protect the weld area from oxygen, and water
vapour.

Depending on the materials being welded, these atmospheric gases

can reduce the quality of the weld or make the welding more difficult

Other arc welding processes use other methods of protecting the

weld from the atmosphere as well

 Shielded metal arc welding (SMAW) - also known as "stick welding",

uses an electrode that has flux, the protectant for the puddle, around
it. The electrode holder holds the electrode as it slowly melts away.
Slag protects the weld puddle from the outside world.
Gas tungsten arc welding (GTAW) - also known as TIG (tungsten,
inert gas), uses a non-consumable tungsten electrode to produce the
weld. The weld area is protected from atmospheric contamination by
an inert shielding gas such as Argon or Helium.
Gas metal arc welding (GMAW) - commonly termed MIG (metal,
inert gas), uses a wire feeding gun that feeds wire at an adjustable
speed and sprays an argon-based shielding gas or a mix of argon
and carbon dioxide (CO2) over the weld puddle to protect it from the
outside world.

METHOD OF WELDING
FOR
TIG WELDING

1.
Put on safety
gear

3.
Plug your foot
pedal into
the machine

2.
Connect the TIG
torch

4.
Select the polarity.

5.
Grind the
tungsten

7.
Set the amperage

6.
Set up the gas flow.

8.
Clean your
welding material

9.
Insert the
tungsten
electrode into its
collet
11.
Tack weld
the parts
together

10.
Clamp the
parts together

12.
Hold the TIG
torch in your
hand

13.
Practice using the foot
pedals to control the
heat

14.
Pick up the
filler rod in
your other
hand

15.
Use your torch to heat up the
base metal

METHOD OF WELDING
FOR
MIG WELDING

1.
Assemble
your safety
gear
3.
Prepare the
area to be
welded in

2.
Select a
comfortable MIG
gun

4.
Obtain the
proper wire

5.
Prepare
the reel

7.
Adjust the
tension

6.
Feed the wire
to the torch
8.
Set the welding
machine
polarity to
DCEP.

9.
Keep a
consistent
electrode
length

10.
Use the
proper
shielding
gas

11.
Weld a joint using a drag or push
welding technique.

EXAMPLE
OF
TIG WELDING
MACHINE

EXAMPLE
OF
MIG WELDING
MACHINE

Shielding gases for MIG welding

The basic gas for MIG welding is inert argon
(Ar) or helium (He), or a mixture of both.
However, small additions of oxygen (O2) or
carbon dioxide (CO2) can further stabilize the
arc, improve the fluidity and also improve the
quality of the weld deposit.
For stainless steels there are also gases
available containing small amounts of hydrogen
(H2).

Shielding gases for TIG

The normal gas for TIG welding is argon or helium, or a
mixture.
In some cases nitrogen (N2) and/or hydrogen (H2) is
added in order to achieve special properties.
For instance, an addition of hydrogen can be used for
many conventional stainless steels to increase
productivity.
Alternatively, if nitrogen is added, the weld deposit
properties can be improved.
Oxidizing additions are not used because they destroy
the tungsten electrode.

TYPES OF CURRENT
Both direct current (DC) and alternating
current (AC) are used for welding.
The form of the weld pool and of the weld
seam can be influenced by current type
and electrode polarity.

EFFECTS OF POLARIITY
Direct current, straight polarity (electrode
negative, DC-EN) deep penetration
Direct current, reverse polarity (electrode
positive, DC-EP) low penetration
Alternating current (AC) medium
penetration

Thus there are three possibilities

for
welding:

1.DC-EP The welding current has to be

reduced 10% of the normal welding
current
2.DC-EN Pure helium is required as a
shielding gas and no reduction of the
welding current is necessary
3.AC The current is required to be
reduced to 50-60% of the normal current

ADVANTAGES
OF
TUNGSTEN INERT GAS
WELDING

 Tungsten Inert Gas Welding produces high

quality welds.
The weld is automatically protected by the inert
gas during the welding process.
No slag is produced.
TIG Welding can be done in any position.

DISADVANTAGES
OF
TUNGSTEN INERT GAS
WELDING

 Tungsten inert gas welding is a slow process.

Highly skilled labour is needed.
Welder is exposed to huge intensities of light
.
TIG welding is more expensive when compared
to MIG welding

ADVANTAGES
OF
METAL INERT GAS
WELDING

 Simple to use
MIG welding is a simple process. In just a few hours,
welders will be able to learn how to MIG weld. As a
matter of fact, the basic MIG welding training can only
last for 20 minutes.
Increases productivity
A lot of welders have improved productivity with the
use of MIG welding. They dont need to regularly
change rods or even repeatedly brush the weld. As a
result, they will able to work faster and in a cleaner
way.
Great and Simple Welds
MIG welding offers better weld pool visibility. The
welding process is very simple and gives you better
control. As a result, you will be able to produce a great
looking weld.

 Versatile
MIG welding has the ability to weld various types of
alloys and metals. You can operate it in a fully
automatic or semi automatic way. As a matter of fact, a
lot of industries are benefitting a lot from the use of MIG
welding. It is used for various metals like copper, mild
steel, aluminum, nickel, magnesium, mild steel, and
many more.
Efficient welding
MIG welding does not only improve the welding speed,
but it as well improves the quality and overall weld
control.
Cleanliness and efficiency
With the use of MIG welding, the loss of alloying
elements will be reduced and minor weld spatter is
produced.

DISADVANTAGES
OF
METAL INERT GAS
WELDING

 Expensive
MIG welding is actually more expensive primarily
because of the complexity of usage. The frequent
replacement of nozzles can actually add up to the total
cost.
Not recommended for outdoor welding
MIG welders are highly discouraged to work outside
because MIG welding uses shielding gas and welding
outside can actually affect the purity of the weld. The
wind outside can compromise the quality of the weld.
Fast Cooling Rates
MIG welding is not covered with slag and so you can
expect that the welded metal will cool at higher rates

 Not recommended for welding thick metals

One of the limitations of MIG welding is its
inability to weld thick metals. Because of the
property of thick metals, MIG weld will not be
able to penetrate deeply. It is only advisable to
use in thin metals.
The use of shielding gas
Replacing the shielding gas may actually take
some time and can cause delay while welding.
Longer preparation time
When welding using MIG, the metal should be
prepared thoroughly. The metal should be free
from dirt and rust to ensure high quality welding.

DEFECTS
OF
TUNGSTEN INERT GAS
WELDING
AND
METHOD TO
PREVENT IT

POOR GAS COVERAGE LEADS TO CONTAMINATION

Weld contamination can occur when shielding gas is not turned

on, there is too little or too much gas shielding or the gas is
blown away

Check the gas cylinder label to make sure youre using the right
type of gas for TIG welding (generally 100 percent argon, or an
argon/helium mix for aluminum)

Consider using a gas lens instead of the standard collet body

to provide better gas shielding.

Check all fittings and hoses for leaks. Use a gas leak detection
fluid, available at most welding suppliers, over the hose and all
fittings. If bubbles form, you have a leak and need to replace
defective components.

 SUGARING ON STAINLESS
Sugaring (oxidation) occurs around the weld
when it is exposed to oxygen in the air. The
best way to prevent sugaring is to ensure you
have adequate gas coverage on the front and
back of the weld and to be sure that you do not
overheat the weld.

TOO MUCH AMPERAGE ON ALUMINUM

Setting the amperage too high on aluminum
creates a wider profile, an ill-defined bead and
can potentially lead to burn-through. To solve
this problem, reduce amperage and/or increase
travel speed.

 CRATERS
Craters occur at the end of the weld and lead to
cracking. Causes include instantly dropping the weld
power and removing the filler rod too quickly. Adjust
your technique and continue to feed the filler rod while
slowly reducing current at the end to fill in the crater.
Using a TIG welder with a crater control function may
also help.
DIRTY BASE AND/OR FILLER METAL
All base and filler metals need to be cleaned, whether
its mill scale, oxide on aluminum, or dirt and grease.
Grind, brush and wipe away all potential contaminants.
For cleaning aluminum, dedicate a stainless steel brush
to the task to prevent contamination from other metals.
Never use brake cleaner!

DEFECTS
OF
METAL INERT GAS
WELDING
AND
METHODS TO
PREVENT IT

Porosity
Gas flow too low or too high
Blocked nozzle
Leaking gas lines
Draughty conditions
Nozzles distance from work is too great
Painted, wet or oily plate
Wet or rusty electrode/wire
Lack of penetration -Current too low
Preparation too narrow
Root face too large
Root gap too small
Worn contact tip causing irregular arc
Incorrect alignment of plates

Undercut -Speed too fast

Current too high
Poor technique
Lack of fusion -Voltage too low
Current too low or too high
Irregular surface
Wrong torch angle

THANK YOU